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I needed a break from the Westers I'm working on so I thought I'd tackle having a go of the armour and pop up a bit of a tut on how I'm doing it.

This may hopefully help out some other Jangos hoping to make their own alloy armour.

Firstly here is the belly piece, cut from 2mm alloy

Now I've taken a piece of 15mm (I think) steel and filed a round edge they I need to 'fold' the alloy over.

Then mount it in the vice were you can see the filed curve

Then sit the alloy over the edge of the steal by a couple mm

Then take the flat of a ball pen hammer and hammer an angle about 5-7mm all the way around the edge, this will allow the piece to look thicker and have more light curve on the edges of the alloy armour (Will make more sense later, stick with me!)

you can see here the hammer marks, this is the face side up

on the underside you should have something like this

Now comes to the curving part

I managed to pickup a piece of PVC from work that was 25mm X 200mm, I found this was perfect for all the armour panels

also wrapped an old tea towel around it to help stop any sharp dints accuring in the armour

now start hammering away, use about 50% of what you would use to hammer a nail in some hard wood.

now ending up with something like this

now get the files out and clean up the edge that has been hit with the hammer

Now you need to file a 45 degree around the edge of the whole panel

Now use a smooth file and clean up 'round' all the work you've done so far